FloTech FT555 Series Automatic Truck Overfill System Tester

FloTech FT555 Series Automatic Truck Overfill System Tester Optic Systems Thermistor Systems Ground Bolt TIM Module 10784PA REV F Dixon Dixon Bayco Division Cincinnati, Ohio

Table of Contents Table of Contents... 2 Introduction... 3 Main Features... 3 FT555 Indicators... 5 Unpack Unit and Initial Setup... 6 Welcome Screen... 7 Power On/Off... 7 Setup Instructions... 8 Selecting Test Option... 11 Performing Automatic Test Fuction... 11 Optic Test... 13 Thermistor Test... 14 Ground Bolt Test... 16 Trailer ID Module Test... 17 Optic and Thermistor Wet Test... 19 Accessories... 21 Technical Support Hotline... 22 Page 2 10784PA REV F FT555 Truck Tester

CAUTION: The FT555 is not certified as suitable for use in a Class I Division 1 hazardous location. You should avoid use in explosive or flammable atmospheres. Troubleshooting: a) Should the FT555 fail to start or shut down during use, check the battery indicator on the welcome screen and or replace the batteries. b) Should the FT555 appear to freeze, remove the batteries to force the unit to power down. Reinstall the batteries and begin test procedure. By removing the batteries you will force the FT555 to restart back to the welcome screen. Technical Support Hotline (877) 582-3569 Contact the FloTech Technical Support Hotline for help: Troubleshooting overfill systems. Verifying defective components To request an RGA for defective FloTech products under warranty. Introduction This Manual describes the features, use, and maintenance of the FT555 Automatic Truck Overfill System Tester. The FT555 is compatible with all makes of Optic sensor systems, 2 wire Thermo-Optic systems, and truck onboard monitor systems regardless of manufacture as long as they are compatible with API RP1004: 2003 recommended practice. Main Features The has the following features: - Automatically test all 4 test functions, Optic, Thermistor, Ground Bolt, and TIM number. - Test all API 5 wire optic sensor systems and report the number of functional / wetted sensors*. - Test 2 wire Thermo Optic sensors and report the number of functional / wetted sensors*. - Monitors up to eight compartments. - Test Ground Bolts with both forward and reverse continuity check. - Read TIM modules and report serial number in display - Perform WET TEST to report when sensors are wetted using integrated beeper. - Configure auto test to perform all selected tests at once. - Configure maximum number of compartments. - Software can be upgraded to include new tests and future expanded testing and troubleshooting capability. * Optic and thermistor tests will only indicate correct number of functional / wetted sensors for systems without an onboard monitor. Page 22 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 3

Accessories Contact Flotech Customer Service (1-800-355-1991) or your local Flotech distributor for pricing and availability information on the following accessories. 1. FT556 USA Test cable package This cable package is suited for use on systems in the US. Package Contents: a. Accessory Adapter b. Optic sensor test cable c. Thermistor sensor test cable d. API Socket extension cable e. Truck ID Modules test cable f. Groundbolt test cable 2. FT557 Non-USA Test cable package This cable package is suited for use on systems outside the USA. Package Contents: a. Accessory Adapter b. Optic sensor test cable c. Thermistor sensor test cable d. API Socket extension cable e. J560 Socket extension cable f. Ground Continuity test cable g. Groundbolt test cable Fig. 1 FT555 Automatic Truck Tester Page 4 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 21

Step 5) The FT555 will repeatedly test for the presence of any wet sensors connected to the Step 6) Dip test a compartment and listen for a number of beeps corresponding to the compartment number that was dipped. The display will also indicate the compartment number of the wet sensor*. Step 7) Continue testing each compartment. Step 8) Stop the wet test by pressing any key. FT555 Indicators A) LCD SCREEN The LCD screen is the main display where test selection, test results, and test instructions are displayed. Screen backlight is enabled using the ON/OFF button. B) ON/OFF BUTTON Press this button to turn the FT555 Automatic Truck Tester on and off. The unit will automatically turn off after 10 minutes. Press and hold this button for 2 seconds and the backlight will illuminate. C) TEST SELECT BUTTON Press this button to cycle through the available tests. NOTE: IF THE TESTER DOES NOT SEE ANY SENSORS OR IS NOT CONNECTED, IT WILL DISPLAY THE ABOVE SCREEN UNTIL IT SEES A SENSOR OR THE TEST IS STOPPED. D) GO BUTTON Press this button to start the selected test. E) WET TEST BUTTON Press this button while in the Optic or Thermistor Test mode and the wet test feature will begin. Pressing any button will stop the wet test. F) SETUP BUTTON Press this button to enter the set up screens. G) BATTERY DOOR Twist to open, hold two D cells, positive points towards battery door (out). * 1.The wet test function will only indicate correct wet compartment number for systems without an onboard monitor. 2. Systems using an onboard monitor will only show sensor 1 wet when any sensor becomes wet. H) ALARM Audible alarm sounds when FT555 Automatic Tester is in WET TEST mode and sensor is wetted. I) API PLUG CONNECTOR API compatible plug with configurable J-Slot pins for both optic and thermistor sockets. Page 20 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 5

Unpack Unit and Initial Setup Step 1) When unpacking the FT555 Automatic Truck Tester you will find the following: a) FT555 Automatic Truck Tester b) Two D size batteries c) Three J-Slot thumb screws d) This instruction manual Step 2) Screw in the three J-Slot Screws into the threads marked O for Optic socket compatibility and into the J-Slot threads market T for thermistor socket compatibility. Step 3) Remove the battery door by turning counter clock wise until door opens. Insert two D size batteries with positive battery terminal facing out of the opening. Reinstall battery door by turning clockwise. DO NOT FORCE BATTERY DOOR OPEN OR CLOSE Step 4) Press the ON/OFF button once. The FT555 will show the Initial System Setup screen shown below: Optic and Thermistor Wet Test NOTE: THE WET TEST FUNCTION IS INTENDED TO BE USED ON WORKING SYSTEMS. IF THE SYSTEM HAS A PROBLEM IT MUST BE REPAIRED BEFORE USING WET TEST. Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body for optic and thermistor style sockets, respectively. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button until the Optic Test or Thermistor Test screen appears, depending on the socket the tester is connected to. Step 4) Press WET TEST button to begin the wet test. Step 5) Complete the Initial System Setup following the setup instructions on page 8. Page 6 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 19

Trailer ID Module Test The Trailer ID Module will be tested and report the 12 digit serial number stored inside the ID module. If there is no trailer ID module or the test fails the screen will show TIM not found Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button five times so the Trailer ID Module Test screen appears. Step 4) Press the GO button to start the test. When the test is complete the screen will report the 12 digit serial number or show TIM not found. Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. Welcome Screen After completing the Initial System Setup the welcome screen will be displayed. This screen will be displayed every time the FT555 Automatic Truck Tester is turned on. The Welcome Screen shows the version software the FT555 is running and the battery health status in bars. 5 bars represent full battery capacity. If 2 or less bars are displayed, a warning beep will sound and a warning message will flash for a few seconds. Batteries should be changed at your next convenience. Power On/Off Press the ON/OFF button once to turn the tester on. Push the button again to turn the tester off. The tester has a display back light for dark conditions. After turning on the tester, press and hold the ON/OFF button for 2 seconds and the back light will turn on. Press and hold again for 2 seconds and the back light will turn off. Page 18 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 7

Setup Instructions At the Press Key screen pressing the SETUP key will enter the setup mode. The first option will be: MAX OPTIC COMPS = # Press the GO button to toggle between 6 and 8 maximum number of compartments. Generally the USA has a maximum of 6 compartments signals per one socket and Canada or European regions will have a maximum of 8. Once the correct number of maximum compartments is displayed, press TEST SELECT button to move to the next SETUP screen. Pin 9/10 Continuity Test Pins 9 and 10 of the API socket will be tested for continuity and the result of the test will be shown as PASS or FAIL on screen. Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button four times so the Ground Continuity Test screen appears. Step 4) Press the GO button to start the test. When the test is complete the screen will report either PASS or FAIL. Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. MAX THERM COMPS = # Press the GO button to toggle between 6 and 8 maximum number of compartments. Generally the USA has a maximum of 6 compartments signals per one socket and Canada or European regions will have a maximum of 8. Once the correct Maximum Compartments count is showing, press TEST SELECT button to move to the next SETUP screen. Page 8 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 17

Ground Bolt Test The Ground Bolt will be tested using the forward and reverse test to confirm proper operation of the diode inside the ground bolt. The tester will report a Pass/ Fail. Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button four times so the Ground Bolt Test screen appears. Step 4) Press the GO button to start the test. When the test is complete the screen will display the PASS / FAIL status. Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. AutoTest Optic/Therm Some regions may not have a need to test optic or thermistor type systems as none are found in that region. Example, trailers in California do not have Thermistor sockets so there is no need to perform the Thermistor test. In this case the Optic test would be enabled. This screen will enable or disable the Optic or Thermistor tests when performing an automatic test of the trailer overfill system. This configuration is only for the automatic testing mode. All four tests are available in the manual test selection. Press the GO button to choose between Enable BOTH, Enable OPTIC or Enable THERM Press the TEST SELECT button to move to the next screen. Auto Test Ground Bolt- OPTIONAL Press the GO button to ENABLE or DISABLE the ground bolt test during the automatic testing. PRESS TEST SELECT button to move to the next screen. Page 16 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 9

Auto Test Ground Continuity System- OPTIONAL 1. Press GO to select either Ground Bolt or Continuity. Once the selection has been made, press TEST SELECT to move to the next screen. See step 2 for Continuity or step 3 for Ground Bolt. 2. Continuity If you selected Continuity, the screen below will be shown, press GO to Enable or Disable the Auto Test function. Press TEST SELECT to move to the Automatic Test Screen, see Performing Automatic Test Function on pg. 11. Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button three times so the Thermistor Test screen appears. Step 4) Press the GO button to start the test. When the test is complete the screen will display the PASS / FAIL status and a wet/dry status for each of the compartments enabled during the setup. A square under the number indicates a dry sensor or a dash under the number indicates a wet or missing sensor. If connected to an Onboard Monitor dashed lines will show and no black bars. Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. 3. Ground Bolt If you selected Ground Bolt, the screen below will be shown, press GO to Enable or Disable the Auto Test function. Press TEST SELECT to move to the Automatic Test screen, see Performing Automatic Test Function on pg.11. Page 10 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 15

Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. Auto Test Truck ID Module- OPTIONAL Press the GO button to ENABLE or DISABLE the Truck ID Module test during the automatic testing. PRESS TEST SELECT button to exit the SETUP mode and return you to the PRESS KEY TEST SELECT screen. Optic pass when connected to sensors is shown above. A black square will be shown for each dry working sensor. Optic pass when connected to an onboard monitor will show dashes for sensor status. Onboard monitors do not have a diagnostic connection to the rack monitor and do not pass the number of good sensors through the onboard monitor to the Thermistor Test The API Thermistor signal from the trailer mounted sensors or onboard monitor will be tested and report a Pass/ Fail. OPERATION NOTE: This tester is not compatible with the old style analog green or silver tipped sensors. These devices require the FT510 tester. Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Page 14 10784PA REV F FT555 Truck Tester Selecting Test Option When at the Press Key screen, each time the TEST SELECT button is pressed the tester will cycle through each of the five available testing modes: AUTOMATIC TEST OPTIC TEST THERMISTOR TEST GROUND BOLT TEST TRAILER ID MODULE TEST Performing Automatic Test Function This test option will automatically test all of the available test options previously enabled in the setup procedure above, and report the findings in a PASS / FAIL screen. Step 1) Press the ON/OFF button to turn on the FT555 Automatic SELECT button one time so the Automatic Test screen appears. Step 2) Press the GO button to start the test. Follow the prompts listed in the display screen. FT555 Truck Tester 10784PA REV F Page 11

Step 5) Press the TEST SELECT button to move on to a new test, press GO to restart the test, or press the ON/OFF button to turn the tester off. Optic Test Step 3) Move the J slot screws to match the J-Slot configuration of the optic Step 4) Connect the tester to the optic Step 5) Press go button to start the test. Step 6) Once the optic portion of the test is complete disconnect the tester from the optic Step 7) Move the J-Slot Screws to match the configuration of the Thermistor Step 9) Connect the tester to the thermistor socket and press the go button to start the thermistor portion of the test. The tester will automatically test the ground bolt and TIM module if these options are enabled in the set up screen. If the tester encounters a failure during any portion of the automatic test it will halt and display the failure on the display. When the test is complete the Screen will display the PASS / FAIL status of each test performed. The API Optic signal from the trailer mounted sensors or onboard monitor will be tested and report a Pass/ Fail. OPERATION NOTE: This test will also report the number of good sensors IF THE SENSORS ARE WIRED DIRECTLY TO THE SOCKET AND NO ONBOARD MONITOR IS USED. Should your trailer have an onboard monitor the tester will test the Onboard Monitor as if it were a single sensor. The status of sensor connected to an Onboard Monitor does not pass through the monitor to the Step 1) Move the J-Slot thumb screws to the correct holes to match the type of socket to be connected. Follow the O and T markings on the plug body. Step 2) Connect the FT555 Automatic Truck Tester to the trailer Step 3) Press the ON/OFF button to turn on the FT555 Automatic SELECT button two times so the Optic Test screen appears. Step 4) Press the GO button to start the test. When the test is complete the screen will display the PASS / FAIL status and a wet/dry status for each of the compartments enabled during the setup. A square under the number indicates a dry sensor or a dash under the number indicates a wet or missing sensor. If connected to an Onboard Monitor dashed lines will show and no black bars. Page 12 10784PA REV F FT555 Truck Tester FT555 Truck Tester 10784PA REV F Page 13